Hey guys. Got another TS185 for a parts bike. Decided to pull the engine apart to get it going. Piston is seized. Need to get it unseized. Been using wd-40 and pb blaster and just muscling it with no luck. Also the kickstarter may be broken/stipped as it does not want to catch. Im guessing somebody kicked it really hard while it was seized and broke it. My worry/question is, to replace this, do i need to crack the crankcase? Im pretty sure i do. Which friggen sucks.

Do you mean the piston is seized inside the cylinder and you cannot make it move? If so, you don't have many options, and none of them are good. Probably the least worst is to try more brute force - with head off and cylinder still bolted to crankcase, try pounding top of piston with hammer and short length of 2" dia or so pipe. At best, you'll get the cylinder off without destroying it and/or the crank.

If you're lucky, the kickstart problem could just be a chipped pawl. I'm not 100% positive but seem to remember you had to split the cases of the earlier TS185s to get to it._________________ Currently - 75 Suz TS250, 02 Kaw ZX-6R

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